Automotive Crash Testing - Shaping the Future of On-Board High-Speed Imaging

At the dawn of the new millennium, AOS Technologies AG set a new standard in high-speed imaging by transforming an academic research prototype into the world’s first self-contained, battery-operated high-speed camera. Housed in a rugged, compact enclosure and built to withstand harsh environments, this breakthrough product—affectionately called the “Black Brick”—was quickly adopted by the global crash testing community.

Thanks to its unmatched portability, built-in battery backup, and reliable data preservation, the Black Brick became the go-to solution for on-board crash tests. For the first time, engineers had a camera they could confidently mount inside vehicles, capturing critical safety data without compromise. It was a defining moment for AOS Technologies and a leap forward for vehicle safety testing worldwide.

From the beginning, AOS has stood for accessible innovation. The Black Brick was not only technically groundbreaking—it was also cost-conscious, making high-speed imaging available to a broader range of users, from OEMs to Tier 2 suppliers.

Over the years, the AOS brand has become synonymous with precision, performance, and Swiss quality. With the launch of newer generations like the S-VIT and S-MIZE, AOS pushed the boundaries further, offering cameras with higher resolution, greater frame rates, and robust designs tailored for extreme conditions.

Beyond cameras, AOS has developed a complete ecosystem—including networkable systems, synchronized illumination, and advanced control solutions—designed to meet the growing demands of modern crash testing environments.

Today, AOS Technologies AG continues to lead the field with a comprehensive range of Swiss-engineered high-speed cameras, trusted by safety labs and automotive manufacturers across the globe. With a strong commitment to engineering excellence and customer support, AOS remains at the forefront of on-board high-speed imaging—driving innovation, one frame at a time.

As crash testing methods have evolved, so too have the demands placed on high-speed cameras. Over time, camera systems have become increasingly specialized, tailored to specific testing environments. This segmentation allows users to benefit from optimized performance and pricing. For example, off-board cameras are typically more cost-effective than the rugged, high-resilience cameras required for on-board testing.

In controlled laboratory settings, such as airbag labs or seatbelt testing facilities, cameras are not exposed to the same physical stresses as in real crash simulations. In these environments, there’s no need for the cameras to withstand extreme acceleration forces.

However, when airbags and restraint systems are tested in barrier tests or sled simulations, the demand for ruggedness increase significantly. In these dynamic scenarios, camera weight, compactness, and ruggedness become critical factors. The equipment must survive harsh mechanical stress while continuing to capture precise, high-quality footage.

Sled testing, in particular, introduces its own set of challenges. With increasing pressure on test labs to accelerate development cycles, cameras must offer fast data download, robust data protection, and software tools that enable efficient and secure workflows.

At AOS, we continuously incorporate feedback from the field. Our engineers have spent decades working closely with test engineers and safety labs worldwide. This direct engagement influences not only the hardware development but also the software capabilities of our high-speed camera systems.

We are especially proud of the application-specific software features developed in collaboration with our customers. Many of these tailored solutions remain supported in current software releases—ensuring long-term usability and a smooth transition to new technologies.

With each generation of products, AOS reaffirms its commitment to reliability, user-driven design, and Swiss engineering excellence in the field of high-speed imaging for vehicle safety testing.

In the majority of crash tests conducted today, standard-built high-speed cameras reliably fulfill their purpose—delivering the critical data needed to develop safer vehicles. However, there are unique testing scenarios where design engineers need to understand complex physics and mechanical interactions that go beyond what off-the-shelf solutions can capture. In these cases, no standard product may be suitable.

This is where AOS Technologies steps in, offering its deep expertise in customized high-speed imaging solutions tailored to the exact requirements of the test.

Take, for example, a case where test engineers needed to evaluate the performance of shock absorbers as a vehicle hit speed bumps at high velocity. Instead of purchasing a standard camera setup that might not have captured the desired data, the engineers consulted AOS in advance to ensure they would receive the right solution for the job.

AOS proposed a custom-engineered update to the camera system, adapting it to fit within the tight space near the shock absorber. Additionally, AOS developed a dedicated trigger device, enabling the camera to autonomously start recording the moment the axle impacted the speed bump—ensuring no critical moment was missed.

While the project required some investment in a custom design, the cost savings from avoiding repeated, inconclusive tests significantly outweighed the additional expense. In the end, the engineers received accurate, actionable data—on the first attempt.

This example illustrates AOS’s commitment to practical, user-driven innovation, ensuring that customers get exactly what they need—even in the most demanding test environments.